Fulcher, Shane (2023) Design & Develop a Low Cost Programmable Logic Controller (PLC) Training Tool, utilising open-source micro-controllers. [USQ Project]
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Abstract
Programmable Logic Controllers (PLC) have increased in usage since their introduction, and the need
for adequately trained programmers has risen along with this increased usage.
The aim for this project was to design and develop a low-cost PLC training tool that makes use of open source microcontrollers to simulate industrial devices commonly found in an industrial control system. Physical requirements for this tool were that it was not to cost more than $1000 AUD, it had to be reasonably portable and that it had to be safe for users. Program requirements for the tool were that it had to allow for programming in at least 3 programming languages, the microcontrollers had to be able to simulate at least 3 standard industrial devices and that users had to be able to easily select these devices.
Previously constructed PLC training tools often fall into one of two categories – advanced pieces of equipment making use of analogue signals and with a professional look to them, but are very expensive, or much cheaper options but are significantly more simplistic in the options available to the user.
The technical requirements for this tool were laid out, detailing the types of industrial devices the microcontrollers were to simulate, and how many inputs and outputs these would require. These requirements led to the selection of a Delta ES3 Series DVP32ES311T PLC for use with the tool. This PLC has capacity for the digital I/O requirements but needed an analogue extension module included to ensure the ability for analogue signals to be utilised. The microcontrollers selected for this tool were the Arduino Uno Rev3. The tool was physically constructed, and sample programs written to test operation. Test scenarios were written for users to follow to aid in their learning.
The tool came in over budget by approximately $160 AUD, but otherwise met all other physical and programming requirements. It was constructed in a portable way and is safe for users to utilise. The PLC can be programmed in Ladder, Structured Text and Sequential Function Chart languages, the microcontrollers can be used as one of up to 7 devices and a selector switch and LCD screen has been added to allow for easy selection of these devices.
The tool was given to users with a wide range of prior PLC programming experience to test its effectiveness and overall feedback from these users was positive. Particularly noteworthy from this feedback was that the users all felt as though they had gained some knowledge and confidence from use of the tool, and the more advanced users enjoyed the ability to practice PID control loop tuning from within the training tool.
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| Item Type: | USQ Project |
|---|---|
| Item Status: | Live Archive |
| Faculty/School / Institute/Centre: | Current – Faculty of Health, Engineering and Sciences - School of Engineering (1 Jan 2022 -) |
| Supervisors: | Hills, Catherine |
| Qualification: | Bachelor of Engineering (Honours) (Instrumentation Control & Automation) |
| Date Deposited: | 24 Sep 2025 05:01 |
| Last Modified: | 24 Sep 2025 05:01 |
| Uncontrolled Keywords: | Programmable Logic Controllers (PLC) |
| URI: | https://sear.unisq.edu.au/id/eprint/52945 |
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